Style 6032 UNIVERSAL II CONTROL INSTALLATION, OPERATION & MAINTENANCE MANUAL

Transcription

1 Style 6032 UNIVERSAL II CONTROL INSTALLATION, OPERATION & MAINTENANCE MANUAL WARRANTY WARRANTY AND DISCLAIMER: We warrant Akron Brass products for a period of five (5) years* after purchase against defects in materials or workmanship. Akron Brass will repair or replace product which fails to satisfy this warranty. Repair or replacement shall be at the discretion of Akron Brass. Products must be promptly returned to Akron Brass for warranty service. We will not be responsible for: wear and tear; any improper installation, use, maintenance or storage; negligence of the owner or user; repair or modification after delivery; failure to follow our instructions or recommendations; or anything else beyond our control. WE MAKE NO WARRANTIES, EX- PRESS OR IMPLIED, OTHER THAN THOSE INCLUDED IN THIS WARRANTY STATEMENT, AND WE DISCLAIM ANY IMPLIED WARRAN- TY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Further, we will not be responsible for any consequential, incidental or indirect damages (including, but not limited to, any loss of profits) from any cause whatsoever. No person has authority to change this warranty. *Unless otherwise provided herein. Akron Brass industrial electronic components & the Severe-Duty Monitor have a one (1) year warranty. Weldon products have a one (1) year warranty (excluding consumable components). Select Weldon LED products carry a five (5) year warranty. For Weldon product returns call Yamaha and Honda products have the manufacturers warranty and Akron Brass disclaims any warranty in respect of those products

2 TABLE OF CONTENTS 0. SAFETY SUMMARY INTRODUCTION Safety Precautions Introduction Description Technical Information Power Requirements Environmental Specifications Requirements INSTALLATION Introduction Unpacking Attaching to vehicle Universal II Cable(s) Installation Monitor/Turret Cable General Monitor/Turret Connector Pin-out DC Power/Signal Cable Generic DC Power/Signal Connector Pin-out Connecting Remote Devices PINS 1 & 2: Vehicle Battery (Power Source) PINS 3 & 4: Auxiliary Battery (Optional) PINS 5 & 6: Hi-Riser or Valve Control PINS 7-9: Logic Outputs PINS 10-12: Relay Contact Output PIN 13: Enable Input PINS 14-21: Switch PINS 22 & 25: Peripheral Power Output PINS 23 & 24: J1939 Vehicle CAN Bus PINS 26 & 27: Not Used PINS 28 & 29: V-MUX Communication Bus (Optional) Pre-operational Check OPERATING INSTRUCTIONS Theory of Operation Initial System Setup Soft Limit Positions, Monitor Orientation, and Obstacle Avoidance Stow Deploy Description of Switch Functions Enable Switch Master Monitor/Turret Up/Down Switch Master Monitor/Turret Left/Right Switch Master Nozzle Pattern Fog/Stream Switch Monitor/Turret Stow/Deploy Switch Slave Monitor/Turret Up/Down Switch Slave Monitor/Turret Left/Right Switch Slave Nozzle Pattern Fog/Stream Switch Flow Rate High/Low Switch Oscillation Set/Start Pause/Resume Switch Discharge On/Remote/Disable Switch Collision Zone Permissive Description of Logic Output Functions Panel LED Discharge Output Gallonage High Output Safe Zone Output Priority of Command Inputs Normal Operation Obstacle Avoidance Operation MAINTENANCE AND SERVICE INSTRUCTIONS Maintenance Instructions Troubleshooting Electrical Operating Environment Common Electrical Issues CAN MESSAGING CAN Address Claimingt Prerequisite Knowledge CAN Physical Layert Address Claimingt General Message Characteristics Appendix A Address Claiming Appendix B Joystick Data UNIVERSAL II VARIANT DETAILS REVISIONS

3 LIST OF ILLUSTRATIONS Figure 1-1 Universal II Control Box... 6 Figure 2-1 Universal II Mounting Hole Locations... 9 Figure 2-2 Monitor Connector (Looking into Universal II) Figure 2-3 DC Power/Signal Connector (Looking into Universal II) Figure 2-4 Vehicle Battery Connection Figure 2-5 Logic Output Wiring Figure 2-6 Relay Contact Output Wiring Figure 2-7 Switch Input Wiring Figure 2-8 Operator Interface Wiring Figure 2-9 J1939 CAN Wiring LIST OF TABLES Table 2-1 Tools and Materials Required for Installation... 8 Table 2-2 Monitor/Turret Connector Pin-out Table 2-3 Generic DC Power/Signal Connector Pin-out Table 2-4 Maximum power wire lengths without Auxiliary battery Table 3-1 Setup mode LED codes

4 SIGNAL WORD DEFINITION SAFETY SUMMARY Per the ANSI Z535.4 standard, the following signal words and definitions are used to indicate hazardous situations: DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices. GENERAL SAFETY PRECAUTIONS The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance. Safety Instruction - Read Manual! Failure to follow operating instructions could result in death or serious injury. Read and understand the operator s manual before using the monitor/turret. Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection, installation, operation and maintenance procedures are not observed. Installation, operation and maintenance to be performed by trained and authorized personnel only. Proper eye protection should be worn when servicing the monitor/turret. SPECIFIC SAFETY PRECAUTIONS The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this publication for emphasis. These are recommended precautions that personnel must understand and apply during specific phases of installation, operation and maintenance. Safety Instruction - Operation! For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code. Safety Instruction Operation! Make sure all power has been disconnected and disable flow prior to performing maintenance. Safety Instruction - Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service. Safety Instruction - Operation! Charge the monitor/turret slowly. Rapid charging may cause a pressure surge that has the potential to cause an injury, or damage to the unit. 4

5 Safety Instruction - Operation! DO NOT stow or deploy the monitor/turret while flowing. Pressing the stow or deploy buttons causes the nozzle to move automatically and the water stream may cause damage to equipment or injury to personnel. Safety Instruction - Operation! Aim the monitor/turret in a safe direction before pumping water through it. (i.e. Away from power lines) Safety Instruction - Operation! DO NOT exceed the maximum pressure or flow ratings of the monitor/turret. Exceeding these ratings may lead to an injury or may cause damage to the monitor/turret. Safety Instruction - Operation! DO NOT install shutoffs on the outlet of the monitor/turret. Shutoffs increase the potential for pressure surges due to water hammer, which have the potential to cause an injury or damage to the monitor/turret. Safety Instruction - Operation! Keep all personnel out of the Danger Zone in front of the outlet of the nozzle when the water source is attached. Dangerous flow velocities can cause serious injury. Safety Instruction Operation! Not designed for explosive environments. Entanglement Hazard! Tangled cables can cause equipment damage. Ensure control cables are not tangled and are free to pay out as monitor/turret is operated. Safety Instruction Operation! All operators must read the Operation section of this manual and be properly trained. Safety Instruction Operation! Use only appropriate Akron Brass Company nozzles. Use of any other nozzles could affect the speed or operation of the monitor/turret. Safety Instruction Installation! Make the connection of the vehicle and/or auxiliary battery the final step. Safety Instruction Operation! The monitor/turret contains moving parts. Keep hands, fingers, and objects away from pinch points. 5

6 CHAPTER 1 INTRODUCTION 1.1 SAFETY PRECAUTIONS Refer to the Safety Summary for precautions to be observed while operating or servicing this equipment. 1.2 INTRODUCTION This manual covers the installation, operation, troubleshooting and maintenance instructions for the Style 6032 Universal Control II. The manual should be reviewed in its entirety. This manual is intended to provide installation, operation and maintenance information for all Universal II configurations. Contact the Akron Brass factory with any additional questions before performing any procedures outlined in this manual. 1.3 DESCRIPTION The Universal II is a product used to control Akron Brass monitors and turrets. The unit is designed for installation on any vehicle for the purpose of providing control of Akron Brass electrically operated monitors or turrets. Refer to Figure 1-1 for identification of the Universal II Control Box. Figure 1-1 Universal II Control Box 6

7 1.4 TECHNICAL INFORMATION Power Requirements The Universal II will operate from either 12 or 24 volt DC power with no customer changes necessary, although Monitors and Turrets must be ordered as 12 or 24 volt for their proper operation. While the Universal II can operate below 10 volts, for optimum performance, a minimum of 11 volts (for 12 volt monitors/turrets, 22 volts for 24 volt monitors/turrets) is required at the Universal II J1 connector. The DC power is internally protected with a 30 amp non-serviceable fuse. This fuse is strictly for wiring protection and should never need replacement under normal conditions. It is recommended that an external 20 amp slow blow fuse be placed in series with the vehicle battery positive lead. The DC power for the Universal II is supplied through a 29 pin Deutsch connector (J1). The DC power connects to pins 1 and 2, and they accept up to 12 AWG wire. See section for pin-out information and schematics and section 2.5 for wiring connection detail. The electronic system has built-in reverse polarity protection. Long runs of cable can introduce voltage/power loss. For long runs, it may be necessary to add an intermediate junction box fed by 10 AWG or heavier wiring with a short 12 AWG run applied to the Universal II. If you need assistance in assessing wiring needs associated with long wiring runs, contact Akron Brass technical support. INPUT POWER REQUIREMENT: 12VDC (Min: 11VDC; Max: 14VDC) OR 24VDC (Min: 22VDC; Max: 28VDC) RECOMMENDED POWER WIRE SIZE: 12VDC: 10AWG 24VDC: 12AWG REQUIRED FUSE: 12VDC: 20 amp Slow Blow 24VDC: 10 amp Slow Blow PEAK AMP DRAW: 50amp for 100ms Environmental Specifications Requirements The Universal II has been designed to be mounted on a vehicle and tolerate the harsh environments encountered in this application. The environmental specifications are listed below: Operating Temperature Range: -40 C - 55 C Enclosure Environmental Rating: IP67 Equivalent 7

8 CHAPTER 2 INSTALLATION Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service. Safety Instruction Installation! Make the connection of the vehicle and/or auxiliary battery the final step. 2.1 INTRODUCTION The Universal II has been designed to provide ease of installation. This section of the manual provides the procedures that must be followed to insure a successful installation. Be sure to read and understand the entire installation procedure before you begin. Table 2-1 provides a list of tools and materials required to install and test the Universal II. Wrenches Deutsch Crimping tool (HDT-48-00) Screwdrivers Wire cutter/stripper #8-32, M4, or M6 Mounting Hardware (4 req d) Multimeter (to verify power is turned OFF) Torque wrench Clean Shop Rags Deutsch contact removal tools Table 2-1 Tools and Materials Required for Installation 2.2 UNPACKING Unpack the Universal II as follows: 1. Carefully open and remove all parts from shipping container. 2. Inspect for any shipping damage. If damage has occurred, notify carrier. 3. Be sure that all components are included and that the required tools are readily available. 8

9 2.3 ATTACHING TO VEHICLE Universal II If the Universal II is to be mounted in a well, be certain that adequate drainage is provided. While the unit has been designed to withstand adverse environmental conditions, it cannot be submerged. The Universal II has two options for mounting: 1. Through hole mounting. The through hole mounting holes provided on the Universal II are.177 inches in di ameter and suitable for #8 or M4 screws. These allow inserting screws from the top side and into threaded holes on the customer s back panel. 2. Mounting with threaded inserts. There are four threaded inserts in the enclosure bottom which are M6 X 1.0. These allow screws to be inserted from behind the customer s back panel and into these inserts on the Uni versal II enclosure bottom. Mounting hole locations for methods 1 and 2 above are shown in Figure 2-1. Please note that it is important that the mounting surface be flat. Sufficient room should also be allowed in mounting location to insure cabling does not have sharp bends close to the connectors. DO NOT OVERTIGHTEN SCREWS AS INSERTS COULD BE DAMAGED OR ENCLOSURE.315 REF Ø.177 HOLE (TYP) REF /64 REF NOTE: ENCLOSURE MAY BE MOUNTED FROM THE TOP WITH A #8 OR M4 SCREW THRU THE ENCLOSURE OR FROM THE BOTTOM WITH A M6x1.0 SCREW. 8-21/32 REF 4-23/32 REF 3-3/16 REF 1 M6 x 1.0 BRASS INSERT MOLDED FLUSH TO BOTTOM SURFACE (TYP) Figure 2-1 Universal II Mounting Hole Locations 9

10 2.4 CABLE(S) INSTALLATION (J2 Connector) Monitor/Turret Cable Monitors and Turrets designed for use with the Universal II come fitted with a harness and connector ready for direct plug-in to the Universal II. While 7.50" these are configured for plug and play installation, removal of the connector to run through a bulkhead may be necessary from time to time. In that event, or in the event of troubleshooting, Table 2-2 is provided for reference General Monitor/Turret Connector Pin-out 14 Pin Male 16 AWG Connector HDP SE-L017 Pin Number Type Potential Function Comments A Analog Common (Ground) B Analog, Switch, PWM In #1 Rotation Position C Analog, Switch, PWM In #2 Elevation Position D Analog, Switch, PWM In #3 Inclination Sensor (Auto-Level) NIVERSAL CONTROL II E Analog Exc. (+5 volts) F Appliance Loop (Tied to Gnd if non Smart Harness ) (LIN Bus) G H-Bridge + (Up) Axis #1 Elevation STYLE H 6032 Pin G - H-Bridge - (Close) J H-Bridge + (Left) Pin H - Axis #1 Rotation K Axis #2 - (Right) L H-Bridge M Axis #3 12/24 N VOLTS DC H-Bridge P Axis #4 EAD OPERATING INSTRUCTIONS BEFORE USE Table 2-2 Monitor/Turret Connector Pin-out + (Fog) - (Stream) + (Low) - (High) Pin A - Analog Common Pin B - Analog, Switch, PWM In #1 Pin C - Analog, Switch, PWM In #2 Pin D - Analog, Switch, PWM In #3 Pin E - Analog Exc. Pin F - Appliance Loop - LIN Pin J - H-Bridge Pin K - Axis #2 Pin L - H-Bridge Pin M - Axis #3 Pin N - H-Bridge Pin P - Axis #4 Pattern Gallonage 18 L M J K H B G C A F D N E P AKRON BRASS COMPANY WOOSTER, OHIO Figure 2-2 Monitor Connector (Looking into Universal II) 10

11 -stable Relay - COM ntact Output - N.O. (Form C) DC Power/Signal Cable (J1 Connector) - N.C. This 29 pin connector provides a connection point for power as well as signals to/from the vehicle. The recommended connector is a Deutsch part number HDP SE. The wires are best crimped in the pins although careful soldering is possible. A crimping tool is available from Ladd Industries part number HDT (AKRON #773426). Please refer to Table 2-3 and Figure 2-3 for pin-out information. NOTE: For ease of installation, a connector kit including connector, pins, and sealing plugs (for unused pins) is available as part number from Akron Brass. The Universal II can also be ordered with this mating connector kit. itch Input #1 itch Input #2 itch Input #3 itch Input #4 itch Input #5 itch Input #6 itch Input #7 itch Input #8 itch Input #9 x. Power (1 Amp) - Data + Vehicle - Data - Can mmon (Ground) - Data + Proprietary - Data - Can - Data + VMUX-COM A - Data - Network-COM B Figure 2-3 DC Power/Signal Connector (Looking into Universal II) STYLE /24 VOLTS DC READ OPERATING INSTRUCTIONS BEFOR K J B H AKRON BRASS COMPANY WOOSTER, OHIO NOTE: THIS DETAIL IS FOR REFERENCE ONLY AND SHOULD NOT BE USED TO CREATE THE GRAPHICS. USE THE ADOBE ILLUSTRATOR FILE TO PRODUCE THE ACTUAL SILKSCREEN GRAPHICS. MA

12 2.4.4 Generic DC Power/Signal Connector Pin-out (Example below from part number Trident Dual Gallonage monitor) 29 Pin Male Mixed AWG Connector HDP SE Pin Number Type Potential Function Comments AWG 1 Power Input + Battery 12 Main Battery 2 (Vehicle) - Battery 12 3 Power Input + Battery Auxiliary Battery 12 4 (Aux. Battery Box) - Battery (Optional) 12 5 H-Bridge + (Open) 16 Electric-Riser or Valve 6 Axis #5 - (Close) 16 7 Logic Output #1 Panel LED 16 Current Sourcing 8 Logic Output #2 Discharge ON 16 (2 Amps Max.) 9 Logic Output #3 High Gallonage Bi-stable Relay Common (Enable Output Contact Output N.O. (1 amp Max.) to Warning Light (Form C) N.C. (1 amp Max.) Circuit or other) Switch Input #1 Enable Input (Fixed Function) Switch Input #2 (+v) Right/Left (-v) Switch Input #3 (+v) Up/Down (-v) Switch Input #4 (+v) Stream/Fog (-v) Switch Input #5 Discharge (+v) Switch Input #6 Gallonage High(+v)/Low(-v) Switch Input #7 Oscillate: Start/Set(+v) Pause/Resume (-v) Switch Input #8 (+v) Deploy/Stow (-v) Switch Input #9 Moniter Specific Option Battery + Out (Peripheral Power) 1 Amp Max Data + To external J Data - vehicle CAN bus 20 Communications to 25 Battery - Out (Peripheral Power) Common-Ground vehicle bus and/or smart Data+ peripherals 16 NOT USED 27 Data Data+ 16 NOT USED 29 Data- 20 Table 2-3 Generic DC Power/Signal Connector Pin-out See Appendix for wiring specific to your monitor. (Reference the part number on your Universal II enclosure to identify your specific monitor configuration. This part number can be found on a label between the J1 and J2 connectors). 12

13 2.5 CONNECTING REMOTE DEVICES PINS 1 & 2: Vehicle Battery (Power Source) The vehicle battery must be connected to pins 1 and 2 of the DC Power/Signal connector. Pin 1 must connect to +Battery and pin 2 must connect to Battery (usually chassis, ground, or common). It is recommended that a 20 amp slow blow fuse be connected in series with the +Battery wire. Refer to section for additional information. Figure 2-4 Vehicle Battery Connection Fig PINS 3 & 4: Auxiliary Battery (Optional) Long power wiring runs can cause excessive voltage drop for 12VDC systems. 24 volt systems are typically not affected by longer runs of power cabling. If your 12 volt system power wiring runs exceed the length in table 2-4, an auxiliary battery is recommended. Pins 3 and 4 provide the connection for an optional auxiliary battery. Pin 3 must connect to auxiliary battery positive, and pin 4 must connect to auxiliary battery negative. These two pins are checked by the Universal II at power-up to see if an auxiliary battery is connected. If one is sensed, it is engaged and a small amount of trickle charge is applied. If this optional feature is not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs. Contact Akron Brass technical support if you have additional questions about the use of this feature. Wire Gauge Max Recommended Cable Length (12VDC systems) 12 AWG 16 Feet 10 AWG 25 Feet Table 2-4 Maximum power wire lengths without Auxiliary battery PINS 5 & 6: Hi-Riser or Valve Control Pins 5 & 6 are optional outputs used to send power to an electric valve motor or an electric monitor riser. Both of these functions are optional. Check wiring diagrams specific to the Universal II being installed to determine which function is enabled. If these outputs are not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs PINS 7-9: Logic Outputs Pins 7 through 9 are current protected solid state power outputs. The output pin is connected to positive system voltage when turned on. Pin 7 powers the operator station LED when installed. Pin 8 is typically used to power an indicator light for the discharge (when software is configured to control a valve with the joystick trigger). It is turned on when the trigger is pushed. Pin 9 is typically used to power an indicator light indicating when the unit is in high gallonage. It is turned off when unit is switched to low gallonage. Please refer to the appendix for the particular version Universal II for their assigned functions. Refer to Figure 2-5 for wiring examples. If any logic outputs are not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs. Figure 2-5 Logic Output Wiring Fig

14 2.5.5 PINS 10-12: Relay Contact Output Pins 10 through 12 connect to an internal latching relay contact. This floating bi-stable contact is dedicated to an interlock function because its state is true regardless of whether the Universal II is powered or not. It is by default assigned to indicating whether or not the monitor/turret is stowed (parked). Because it is floating, it may be connected to either battery positive or negative for driving loads such as pilot lights or external relays. Refer to Figure 2-6 for examples of connecting an external load. This contact is not rated for dry circuits and so should have at least a 10 ma load minimum. It does not have arc suppression. Therefore, if driving a relay coil, external suppression should be provided. A typical usage would be for a warning light to alert the driver the monitor/turret is not properly stowed/parked. If this optional feature is not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs. or Figure 2-6 Relay Contact Output Wiring PIN 13: Enable Input Switch Input #1 (Pin 13) is dedicated to interlock functionality. NOTE: This switch input must be connected to battery common or ground in order for the Universal II to function. This input is typically used for connecting a parking brake switch to this input to prevent operation of the monitor/turret without first setting the parking brake. If interlock functionality is undesired, this pin should be hard-wired to Battery common or ground PINS 14-21: Switch Inputs Switch Inputs #2 to #9 (pins 14 to 21) are primarily intended for toggle switch inputs. Their function varies depending on configuration. An Akron Brass Operator Station can be used or user can provide their own switch inputs. Please refer to the Appendix for the particular version Universal II for their assigned function. The Universal II version is identified by a barcode label on the outside of the enclosure between the J1 and the J2 connectors that includes the part number (6032XXXX) and revision level. Each input recognizes three distinct states open, connected to +Bat, and connected to Bat. A typical toggle switch connection is shown in Figure 2-7. Use of relay contacts could also be implemented if care is taken to insure there is never a case in which the battery is shorted out. A form C contact is a good choice in which the common is tied to the switch input. High/Low Gallonage control would be an example of where relay contacts could be used. Figure 2-8 shows connection of an Akron Brass switch box. Note the hard-wired connection into Switch Input #1 to continuously enable the monitor. Also note that pins 22 and 25 supply power to the operator station LED. See section for more detail. Figure 2-7 Switch Input Wiring Fig. 2-7 Unused switch input pins should be fitted with Deutsch pin sealing plugs. These are included in the connector kit if purchased from Akron Brass. NOTE: If any of the switch inputs are still connected to battery + after power is removed from the Universal II (i.e. the switch inputs are not powered directly from the U2 as shown), the control will not properly shut down due to leakage currents through the inputs. Insure that battery + for the switch inputs is disconnected along with power to the Universal II. 14

15 TO MONITOR J UNIVERSAL II VEHICLE BATTERY (+) VEHICLE BATTERY (-) AUXILIARY BATTERY (+) AUXILIARY BATTERY (-) MOTOR #5 OUTPUT MOTOR #5 OUTPUT SOURCE OUTPUT #1 SOURCE OUTPUT #2 SOURCE OUTPUT #3 RELAY FLOATING CONTACT (COM) RELAY FLOATING CONTACT (N.O.) RELAY FLOATING CONTACT (N.C.) SWITCH INPUT #1 SWITCH INPUT #2 SWITCH INPUT #3 SWITCH INPUT #4 SWITCH INPUT #5 SWITCH INPUT #6 SWITCH INPUT #7 SWITCH INPUT #8 SWITCH INPUT #9 AUX. POWER OUT (1 AMP) VEHICLE CAN HI VEHICLE CAN LO COMMON (GROUND) AKRON BRASS CAN HI AKRON BRASS CAN LO WELDON V-MUX COM A WELDON V-MUX COM B (PIN GAUGE) 12AWG. 12AWG. 12AWG. 12AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 16AWG. 20AWG. 16AWG. 20AWG. 16AWG. 16AWG. 20AWG. 20AWG. 16AWG. 16AWG. 20AWG. 16AWG. 20AWG. J TO VEHICLE BATTERY (+) (+12V OR +24V) WHITE 11 BROWN BLUE YELLOW GREEN RED BLACK SWITCH 1 (GREEN) SWITCH 2 (YELLOW) 11 SWITCH 3 (BROWN) SWITCH 4 (BLUE) OPERATOR INTERFACE OR EQUIVALENT CUSTOMER WIRING USES DEUTSCH #HDP SE REFER TO APPROPRIATE UNIVERSAL II DRAWING FOR PIN CONFIGURATION AND I/O ASSIGNMENT Figure 2-8 Operator Interface Wiring PINS 22 & 25: Peripheral Power Output To simplify wiring, power is provided out to peripheral devices such as joysticks, operator stations, direction indicators, etc. Pins 22 and 25 provide +Battery and Battery power out respectively. This output is internally protected by a 1 amp self-resetting fuse. Refer to Figure 2-8 for example of how this is used with an operator station. If this optional feature is not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs PINS 23 & 24: J1939 Vehicle CAN Bus The Universal II J1939 Vehicle CAN Bus is available on pins 23 and 24. Pin 23 is CAN-HI, and pin 24 is CAN-LO. Preferred connection to these pins should be made with J1939/11 compliant wiring. See Figure 2-9 for additional details. NOTE: Termination resistors are critical to reliable performance. If this optional feature is not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs. 15

16 C 120 ohm A A C C ITEM MANUFACTURER DESCRIPTION A Deutsch IPD HDP SE PLUG B Deutsch IPD DT06-3S-EP11 PLUG w/ W3S-P012 WEDGE LOCK C Deutsch IPD DT06-3S-P006 TERMINATING RESISTOR ASSEMBLY D Deutsch IPD DT04-3P-P007 "Y" RECEPTACLE E Deutsch IPD DT06-3S-EP11 PLUG w/ W3S-1939-P012 WEDGE LOCK F Deutsch IPD DT06-4S w/ W4S WEDGE LOCK G Champlain Wire Raychem Northwire Judd Wire SAEJ1939/1802SHBLK or 2018E0309 or FJ or M B B B B CAN JOYSTICK (6035) CUSTOMER WIRING USES DEUTSCH DT06-4S PLUG YELLOW GREEN YELLOW GREEN G DIRECTION INDICATOR (6036) CUSTOMER WIRING USES DEUTSCH DT06-4S PLUG TO BATTERY POSITIVE (+) YELLOW GREEN A A C C A A A C C C A C B B B B B B SHIELD DRAIN WIRE MAY BE OPTIONALLY CONNECTED HERE. IF SO, MUST NOT BE CONNECTED ELSEWHERE TO COMMON OR BATTERY NEGATIVE (-) (SEE J1939/11 SECTION 5.2.4) D D D C C A A C C YELLOW A A C B GREEN G E E B F E E NETWORK LENTGH (TERMINATOR TO TERMINATOR) NOT TO EXCEED 40 METERS B F UNIVERSAL II (6032) (CONNECTOR J1) CUSTOMER WIRING USES DEUTSCH HDP SE VEHICLE CAN HI VEHICLE CAN LO COMMON YELLOW GREEN G C A TO BATTERY POSITIVE (+) **INSTEAD OF TERMINATING RESISTOR, MAY CONTINUE ON TO REMAINING VEHICLE CAN NETWORK** SUGGESTED PARTS LIST B B G G 120 ohm MUST NOT EXCEED 1 METER LENTGH MUST NOT EXCEED 1 METER LENTGH MUST NOT EXCEED 1 METER LENTGH - KEY CODE - KEY CODE - KEY CODE A - KEY CODE - KEY CODE A A C A C - KEY CODE A - KEY CODE A C - KEY CODE B C B B B C - KEY CODE B B Figure 2-9 J1939 CAN Wiring 16

17 PINS 26 & 27: Not Used It is recommended these pin locations be fitted with Deutsch pin sealing plugs PINS 28 & 29: V-MUX Communication Bus (Optional) Connection to a VMUX communications bus is available on pins 28 and 29. Pin 28 is VMUX A and Pin 29 is VMUX B. Not all software versions support VMUX communication. Contact Akron Brass technical support for details of your particular version. If this optional feature is not used, it is recommended these pin locations be fitted with Deutsch pin sealing plugs. 2.6 PRE-OPERATIONAL CHECK For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code. Before operating the Universal II and monitor/turret, be sure that there are no potential obstructions. Visually inspect the unit for any damage. If damage is apparent, do not use the system. Have it serviced prior to use. Check for any objects which might obstruct motion of the monitor/turret or cause binding. Remove any material that may hinder monitor/turret function. 17

18 CHAPTER 3 OPERATING INSTRUCTIONS All operators must read the Operation section of this manual and be properly trained. Keep personnel clear of monitor/turret discharge path during operation. For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code. 3.1 THEORY OF OPERATION The Universal II control system is based on a distributed intelligence control structure. Each device in the system has a circuit board with an embedded micro controller. These devices include (but are not limited to): the 6032 Universal II Control Box, the 6033 Mini Universal, the 6034 CAN Operator Interface, the 6035 CAN Joystick, the 6036 CAN Direction Indicator, the 6037 CAN Wireless Interface, and the associated handheld Remote Control(s). These boards talk to each other over an SAE J1939 compliant CAN serial communications link. The 6032 Control Box at the heart of the system is a software-defined universal controller. Its inputs and outputs are pre-programmed at the factory to match the particular monitor/turret it is used with. Please refer to the Appendix for the particular version Universal II for their assigned function. The Universal II version is identified by a barcode label on the outside of the enclosure between the J1 and J2 connectors that includes the part number (6032XXXX) and revision level. Additionally, there are many parameters that can be configured by the user. These can be configured using the processes defined in section INITIAL SYSTEM SETUP The Universal II allows many configuration options during setup. The following functions can be configured in the setup mode: Right, Left, Up and Down soft limits Monitor orientation (sideways or inverted mounting) Obstacle Avoidance Stow and Deploy positions Position Sensor zero Restore Factory Defaults 18

19 To enter the setup mode for the above functions, follow these steps: 1. Turn power off to Universal II 2. Press and HOLD stream switch (can be done on Joystick or toggle switch box) 3. Turn power on to Universal II while continuing to hold the stream switch 4. Wait 3-4 seconds and release the stream switch The Universal II should now be in setup mode. When it is setup mode, the LED on the operator station will be slowly blinking (a short blink followed by a long pause). If it is not slowly blinking, turn the power off and repeat steps 1-4. All setup functions options except Stow and Deploy can be scrolled through by pressing the stream switch. Each time the stream switch is pressed, another function is active for configuration. If a function is configured and saved using the fog switch, it will automatically move to the next function. For example, the first time the stream switch is pressed, the right soft limit is ready for programming (LED CODE 1-1). If it is pressed again, the left soft limit is ready for programming (LED CODE 1-2). If the left soft limit is set and the fog switch is pressed, it will automatically move to the up soft limit without having to press stream again (LED CODE 1-3). Alternately, activating the Stream command will abort this mode without storing the position and forward the user to the next Soft Limit Position mode. Entering the Stow and Deploy programming modes can only be accomplished by activating the Stow or Deploy switch while at the start of the setup menu (LED CODE 1 Slow blink). (See sections and for more detail). To aid in determining which setup menu the Universal II is in, the LED on the operator station has been programmed to blink a different code for each function. Table 3-1 below lists the LED codes for each function. The codes have two parts. The LED code will start with either one or two short blinks, a short pause, another series of short blinks, and then a long pause. The first number in the LED code is the one or two blinks and the second number is the second series of blinks before the long pause. Any of the following functions may be configured by stopping at that function and performing the operation (see sections for detailed information on configuration of each function). Setup Menu Function LED code Setup Mode Start 1 slow blink Right Soft Limit 1-1 Left Soft Limit 1-2 Up Soft Limit 1-3 Down Soft Limit 1-4 Monitor Orientation 1-7 Zero Position Sensors 1-8 Restore Factory defaults 1-9 Obstacle avoidance Disable 2-1 Obstacle Avoidance Manual Operation 2-2 Obstacle Avoidance Auto Operation 2-3 Obstacle Avoidance Learn 2-4 Cafs Dry Valve Position 2-5 Cafs Wet Valve Position 2-6 Stow/Deploy Rotation Position 2-7 Collision Zone ON 2-8 Collision Zone OFF 2-9 Electric Riser OFF 3-1 Electric Riser ON 3-2 Stow 1-5 Deploy 1-6 Table 3-1 Setup mode LED codes 19

20 While any and all of these configurations are optional, if a monitor/turret orientation is mounted sideways or inverted, the monitor orientation will need to be configured for proper operation. If at any point it is determined that an undesirable mode is active, it is possible to abort the mode by removing power to the Universal II prior to activating the Fog input. If it is determined that an undesired function may have been saved, it may be desirable to use the Restore Factory Defaults function (LED CODE 1-9). When all desired changes have been made, cycling power will return the monitor/turret to normal operation with the changes made in effect. The changes can also be saved by pressing the fog switch when in setup start mode (one single blink) Soft Limit Positions, Monitor Orientation, and Obstacle Avoidance The monitor/turret may have a range of motion greater than necessary for a given application. For instance, a monitor/turret with a rotation range of 355 would have too much rotational range for use as a bumper turret. Soft limits can be set to shorten the rotational and elevation range. NOTE: Use of this function will clear all stored obstacle avoidance option profile data and require the obstacle avoidance to be re-programmed. Factory defaults are set to a soft limit location beyond the hard stops so that the monitor will have full range of motion between hard stops until the soft limits are set. The soft limits are strictly OPTIONAL and do not need to be configured Right (Blink Code 1-1) In this mode, Up, Down, Left, and Right functions will be active. Move the monitor to the right position that is to be set as the soft limit. When in the position desired for the right soft limit, press the Fog switch. The new right soft limit is now set and the left soft limit is active for programming. Alternately, activating the Stream command will abort this mode without storing the position and forward the user to the left Soft Limit Position mode Left (Blink Code 1-2) In this mode, Up, Down, Left, and Right functions will be active. Move the monitor to the left position that is to be set as the soft limit. When in the position desired for the left soft limit, press the Fog switch. The new left soft limit is now set and the up soft limit is active for programming. Alternately, activating the Stream command will abort this mode without storing the position and forward the user to the up Soft Limit Position mode Up (Blink Code 1-3) In this mode, Up, Down, Left, and Right functions will be active. Move the monitor to the up position that is to be set as the soft limit. When in the position desired for the down soft limit, press the Fog switch. The new up soft limit is now set and the down soft limit is active for programming. Alternately, activating the Stream command will abort this mode without storing the position and forward the user to the down Soft Limit Position mode Down (Blink Code 1-4) In this mode, Up, Down, Left, and Right functions will be active. Move the monitor to the down position that is to be set as the soft limit. When in the position desired for the down soft limit, press the Fog switch. The new down soft limit is now set and the monitor orientation setup is active for programming. Alternately, activating the Stream command will abort this mode without storing the position and forward the user to the monitor orientation Soft Limit Position mode Monitor Orientation (Blink Code 1-7) There are instances when it is desirable to mount the monitor/turret other than in the factory default flange on the bottom position. In those instances, this function prevents having to change the wiring of switches or re-programming CAN joysticks to handle changes in Up/Down Left/Right behavior. It is only necessary to program the monitor orientation when the monitor/turret is mounted on its side or upside down. When in this mode, determine which of the four inputs (Up, Down, Left, or Right) results in Up movement. The last movement made prior to pressing the Fog switch will be used as the new Up motion and will remap the other inputs accordingly. Move the monitor in whatever the current Up motion is and then press the Fog switch. The new orientation is now saved and the Position Sensor Zero setup mode is active for programming. If the Stream switch is pressed at any time before the Fog switch, the monitor orientation will remain unchanged and the user will be placed in Position Sensor Zero mode. NOTE: Use of this function will clear all stored obstacle avoidance profile data and require the obstacle avoidance option to be re-programmed. 20

21 Position Sensor Zero (Blink Code 1-8) It is often difficult for the vehicle manufacturer to mount the monitor/turret in the precise position where straight ahead and level matches the calibration of the monitor/turret at the Akron Brass factory. Use of this mode allows the user to re-zero the sensors at the desired straight ahead and level position. First, use the Up/Down Left/Right to position the monitor/turret straight ahead and level. When the desired position has been reached, press the Fog switch. The new zero position is now set and the Restore Factory Defaults mode is now active for programming. If no Fog action is taken but Stream is activated, the position sensor values will remain unchanged and the user will be forwarded to the Restore Factory Defaults mode. NOTE: All soft limit, stow/deploy positions, and CAN position reporting will be impacted by this operation. If needed, this setting should be done prior to setting other soft limits. NOTE: Use of this function will clear all stored obstacle avoidance profile data Restore Factory Defaults (Blink code 1-9) Occasionally, it may be desirable to return to factory defaults. To restore factory defaults when in this mode, press the fog switch. This will clear all user settings and return the user to the beginning of setup. The following settings will be reset to factory default: All soft limits will get set to maximum. Position sensor zero values will return to the values set at the factory. Monitor orientation will get reset to standard position. Stow and Deploy positions are reset to zero degrees as established at the factory. Obstacle Avoidance profile data is cleared and disabled. It is possible to abort this mode prior to activating the Fog input by simply removing power to the Universal II. Alternately, activating the Stream input will forward the user to Disable Obstacle Avoidance mode (Blink Code 2-1) Disable Obstacle Avoidance (Blink Code 2-1) Once in this mode, to disable obstacle avoidance, press the fog switch once. This will disable Obstacle Avoidance, clear the Obstacle Avoidance profile, and returns the user to the beginning of setup mode. Factory default is obstacle avoidance disabled. Activating the Stream input will forward the user to Obstacle Avoidance Manual Operation mode Obstacle Avoidance Manual Operation (Blink Code 2-2) Manual operation mode requires the operator to manually move the monitor around obstacles. When an obstacle is encountered, movement in that direction stops until the operator moves the monitor/turret around the obstacle. Once in this mode, to select manual obstacle avoidance, press the fog switch once to set manual obstacle avoidance operation. Manual obstacle avoidance is now active. Activating the Stream input will forward the user to Obstacle Avoidance Auto Operation setup mode Obstacle Avoidance Auto Operation (Blink Code 2-3) Auto operation mode does not require the operator to move up and down to go around an obstacle. When an obstacle is encountered, movement in that direction stops and the Universal II automatically navigates up, over, and back down) around the obstacle as long as the joystick is maintained inthe horizontal command (right or left). Once in this mode, to select auto obstacle avoidance, press the fog switch once to set auto obstacle avoidance operation. Auto obstacle avoidance is now active. Activating the Stream input will forward the user to Obstacle Avoidance Learn setup mode. 21

22 Obstacle Avoidance Learn (Blink Code 2-4) This function elecation sets The Lower Limits across the horizontal range of the monitor. For instance, a monitor located on the center of a cab roof might need to raise the nozzle slightly to avoid hitting the corners of the cab as it sweeps from side to side. Use of this mode allows the user to program a horizontal profile that will go around one or more obstacles. As the monitor is moved from side to side (either right to left, or left to right), the vertical position values are stored at one degree increments. Backing up will overwrite previous data. If a horizontal area is not learned, that area will be inaccessible later. To program an obstacle avoidance profile, follow these steps: 1. Enable either manual or automatic obstacle avoidance. 2. Move turret to the lower left or right or lower right soft limit. 3. Sweep until the first obstacle is encountered. Stop movement before the obstacle is reached. 4. Move horizontally up over and back down until the obstacle is cleared. 5. Continue moving toward the opposite side. Repeat steps 2 and 3 if any other obstacles are encountered. 6. When the opposite horizontal soft limit is reached. Press the fog switch. The new Obstacle avoidance profile is now saved and the user is returned to the beginning of the setup mode. The same procedure can also be followed from right to left. It is important that the entire rotational range is covered during the programming procedure. Activating the Stream input at any time will discard any profile data that has already been saved and return the user to the beginning of setup mode CAFS Dry position learn mode (Blink Code 2-5) This function sets the discharge valve open position for a dry compressed air foam setting. Essentially, this setting will allow the valve to open to a programmable position based on time. Before entering the CAFS programming mode, make sure the WATER ON/REMOTE/OFF toggle switch is in the REMOTE position. Enter the CAFS DRY learn mode by pressing the Stream switch until the blink code of 2-5 is obtained on the operator station LED. The control system will automatically close the discharge valve if it is not closed. To set the valve open position, use the Water ON/REMOTE/ OFF toggle switch. The discharge valve will move toward open when the switch is in the on position and toward closed when the switch is in the off position. If you move too far open, you can use the Water Off switch to move the valve back toward closed. When the Water switch is in the center position ( Remote ) the valve will stop moving. To save the final valve position, press the FOG switch on the joystick or operator station. Pressing the Stream switch at this point will put you into CAFS Wet position setting mode CAFS Wet position learn mode (Blink Code 2-6) - This function sets the discharge valve open position for a wet compressed air foam setting. Essentially, this setting will allow the valve to open to a programmable position based on time. Before entering the CAFS programming mode, make sure the WATER ON/REMOTE/OFF toggle switch is in the REMOTE position. Enter the CAFS WET learn mode by pressing the Stream switch until the blink code of 2-6 is obtained on the operator station LED. The control system will automatically close the discharge valve if it is not closed. To set the valve open position, use the Water ON/REMOTE/ OFF toggle switch. The discharge valve will move toward open when the switch is in the on position and toward closed when the switch is in the off position. If you move too far open, you can use the Water Off switch to move the valve back toward closed. When the Water switch is in the center position ( Remote ) the valve will stop moving. To save the final valve position, press the FOG switch on the joystick or operator station. Pressing the Stream switch at this point will take you back to the beginning of setup mode Stow Rotation Position (Blink Code 2-7) This function sets the horizontal position that the 3440 DeckMaster with position feedback monitor must achieve before it will begin moving the middle elbow to the stowed position. The default position is straight ahead. This only applies to the 3440 DeckMaster with the position feedback option XT Zone Interlock On (Blink Code 2-8) - This function enables the extra travel zone interlock on a 3598 StreamMaster XT monitor. When this function in enabled, the elevation motor will stop at 90 degrees above horizontal until a permissive input is received on J1 pin 21 on the U2 logic box. When the permissive signal is present, the monitor will be allowed to move into the extra travel zone (+90 to +120 degrees). If the monitor is in the extra travel zone and the permissive signal is removed, the monitor will lower itself back to the +90 degree position. The factory default for this function is on. This function only applies to the 3598 StreamMaster XT monitor. 22

23 XT Zone Interlock Off (Blink Code 2-9) -This function turns off XT Zone Interlock (see ) and allows the 3598 StreamMaster XT monitor to freely move into the extra travel zone (+90 to +120 degrees). This function only applies to the 3598 StreamMaster XT monitor Electric Riser Off (Blink Code 3-1) This function disables the electric riser (Style 3406) when used with the 3440 DeckMaster monitor. This is the factory default setting. This function only applies to the 3440 DeckMaster monitors, both with and without the position feedback option. When off, the electric riser will not move during the stow or deploy sequence Electric Riser On (Blink Code 3-2) This function enables the electric riser (Style 3406) when used with the 3440 DeckMaster monitor. When on, during deploy, the electric riser will lift the monitor up and then the monitor will deploy. During stow, the monitor will stow and then the electric riser will retract Stow (Blink code 1-5) To enter the Stow programming mode, momentarily press the Stow switch when in the beginning of setup mode (1 slow blink). To verify you are in the Stow programming mode, verify that the Panel LED is blinking a pattern of one short blink, a short pause, then five short blinks, and a long pause. While in this mode, Up, Down, Left, and Right functions will be active. Movement will not be constrained by soft limits, allowing a stow position that is outside the normal operational envelope. However, obstacle avoidance will be disregarded while learning the stow position, so care must be taken to avoid obstacles manually while learning the stow position. When in the desired stow position, there are two methods of completion. Activating the Fog command will save the position and cause the nozzle to go to the fog setting during the stow sequence, and return the user to the beginning of the setup mode. Activating the Stream command will save the position and cause the nozzle to go to the stream setting during the stow sequence, and return the user to the beginning of setup mode. This mode may be aborted by activating the Stow input again which will return the user to the beginning of setup mode. The factory default stow position is straight ahead and level as defined by the sensor zeroing (see section ) Deploy (Blink code 1-6) To enter the Deploy programming mode, momentarily press the Deploy switch when in the beginning of setup mode (1 slow blink). To verify you are in the Deploy programming mode, verify that the Panel LED is blinking a pattern of one short blink, a short pause, six short blinks, and a long pause. While in this mode, Up, Down, Left, and Right functions will be active. Movement will be constrained to whatever soft limits that are in effect. However, obstacle avoidance will be disregarded while learning the deploy position, so care must be taken to avoid obstacles manually while learning the deploy position. When in the desired deploy position, there are two methods of completion. Activating the Fog command will save the position and cause the nozzle to go to the fog settingduring the deploy sequence, and return the user to the beginning of the setup mode. Activating the Stream command will save the position and cause the nozzle to go to the stream setting during the deploy sequence, and return the user to the beginning of setup mode. This mode may be aborted by activating the Deploy input again which will return the user to the beginning of setup mode. The factory default deploy position is straight ahead and level as defined by the sensor zeroing (see section ). 3.3 DESCRIPTION OF SWITCH FUNCTIONS The Universal II has nine switch inputs located on the vehicle connector (see Figure 2 3 and Table 2 3). Below are the various functions that the Universal II switch inputs can provide. Each variant of 6032 will have some combination of these, but not necessarily all or in the order presented here. These inputs are typically driven by variants of the style 6041 Toggle switch Operator Station. NOTE: The Universal II switch inputs are three-state inputs. Refer to section for additional information and proper wiring Enable Switch (J1 Pin 13) This switch input functionality is provided across the full line of 6032 variants. It provides capability for interlocking operation of the monitor/turret with the state of condition(s) outside the system for safety purposes. Examples might be a parking brake set, a lighting mast retracted, or a roof ladder deployed. This input must not be left floating or disconnected if the monitor/turret is to operate. Connection to either +Battery or -Battery (usually ground) by switch, hardwiring, or some other appropriate device will enable monitor operation. 23